Avid Technology X0 Trail Service Manual Download Page 1 | Manualshive

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2012

X0

Trail

™

Service Manual

GEN.0000000004233 Rev A

© 2012 SRAM LLC

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Summary of Contents for X0 Trail

Page 1: ...2012 X0 Trail Service Manual GEN 0000000004233 Rev A 2012 SRAM LLC ...

Page 2: ...eptable quality and the failure does not amount to a major failure Limitations of Liability To the extent allowed by local law except for the obligations specifically set forth in this warranty statement in no event shall SRAM or its third party suppliers be liable for direct indirect special incidental or consequential damages Limitations of Warranty This warranty does not apply to products that ...

Page 3: ...ervice 6 caliper overhaul 14 caliper exploded view 14 Parts and tools needed for service 14 troubleshooting 15 hose length adjustment 21 Parts and tools needed for service 21 brake bleed procedure 25 Parts and tools needed for service 25 PAD replacement INSTRUCTIONS 31 disc brake pad and rotor bed in procedure 32 ...

Page 4: ...SAFETY FIRST At SRAM we care about YOU Please always wear your safety glasses and protective gloves when servicing your products Protect yourself Wear your safety gear ...

Page 5: ...low any brake fluid to come in contact with the brake pads If this occurs the pads are contaminated and must be replaced For best results use only Avid High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid b ra k e ser v i ce o v er v i ew Avid brake systems need to be serviced periodically to optimize braking function If br...

Page 6: ...ing Parts an d t o o l s nee d e d f o r ser v i ce Safety glasses Nitrile gloves Oil pan Isopropyl alcohol Clean lint free rag Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid DOT Grease or DOT 5 1 or 4 compatible grease Bench vise Long tipped snap ring pliers Pick with a 90 degree bent tip 3 mm hex wrench tooled reach adjust models only T10 T25 TORX wrench T10 T25 TORX bit socket 11 mm...

Page 7: ...e an 8 mm flare nut wrench to remove the hose compression nut Pull the brake hose and compression fitting from the brake lever body 3 Pour the brake fluid into an oil pan Squeeze the lever to pump excess brake fluid from inside the lever assembly If the system has been contaminated with the wrong fluid flush all the parts with soapy water rinse and allow to dry prior to rebuilding Install all new ...

Page 8: ...h adjust models Use a 3 mm hex wrench to turn the reach adjuster 7 Remove the lever from the lever body 8 Clamp a 2 mm hex wrench into a bench vise with the tool positioned vertically Insert the lever body on the wrench through the fluid flow port in the master cylinder head Place a clean rag under the lever body to wipe up any fluid that may spill out Spring anchor tab Return spring eyelet 2 mm ...

Page 9: ...rectly into the lever body while performing this step The internal piston spring assembly is preloaded and will come out of the lever body quickly which can result in injury Wear safety glasses 10 Lubricate a new piston bladder snap ring assembly by dipping it into Avid High Performance 5 1 DOT Fluid You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant ...

Page 10: ...nto the lever body and secure the snap ring in its groove Orient the snap ring eyelets opposite the opening in the lever body You can also use a 10 mm deep socket against the snap ring to push the piston bladder snap ring assembly into the lever body If you push the snap ring past its groove you can use the 2 mm hex in the vise to push on the assembly from inside the fluid flow port which will sea...

Page 11: ...12 Insert the lever blade into the lever body Thread the reach adjuster onto the pushrod and turn it clockwise an additional 5 6 complete turns Tooled reach adjust models Use a 3 mm hex wrench to turn the reach adjuster ...

Page 12: ... of the lever return spring onto the spring anchor tab on the snap ring 14 Use a T10 TORX wrench to install the pivot bolts into both sides of the lever Use a torque wrench with a T10 TORX bit socket to tighten the pivot bolts to 1 1 1 2 N m 10 11 in lb T10 1 1 1 2 N m 10 11 in lb ...

Page 13: ...sion nut to 4 9 5 4 N m 43 48 in lb Spray isopropyl alcohol on the lever and clean it with a rag Slide the hose boot onto the compression nut 16 Reinstall the brake lever to the Discrete clamp MMX or XLoc Use a torque wrench with a T25 TORX bit socket to reinstall the brake clamp bolt into the Discrete clamp MMX or XLoc and tighten it to 5 6 N m 44 52 in lb 8 mm 11 mm 4 9 5 4 N m 43 48 in lb T25 5...

Page 14: ...jo bolt Parts an d t o o l s nee d e d f o r ser v i ce Safety glasses Nitrile gloves Oil pan Isopropyl alcohol Clean lint free rag Avid High Performance 5 1 DOT Fluid or DOT 4 Fluid or Avid DOT Grease or DOT 5 1 or 4 compatible grease Air compressor with rubber tipped blow gun chuck Soft rubber mat or small section of butyl inner tube Needle nose pliers Pick with a 90 degree bent tip 2 5 5 mm hex...

Page 15: ...e pads nearly contact one another 4 Push the XO Trail pad spreader clip in between the pads to spread the pads to the full width of the clip 5 Remove the clip 6 Repeat steps 3 5 several times 7 Reinstall the wheel 8 Squeeze the lever several times to position the pads at the proper distance from the rotor 9 Center the caliper on the rotor if necessary 10 Spin the wheel and check brake function All...

Page 16: ...er bolt from the caliper 3 Pull on the brake pad tabs to remove the pads and pad spreader clip If the total thickness of the backing plate and pad friction material is less than 3 mm the brake pads need to be replaced 4 Use an 8 mm open end wrench to remove the banjo bolt and a T25 TORX wrench to remove the caliper body bolt Brake fluid will leak so hold the caliper over a container to catch the f...

Page 17: ... to force air into the caliper until both pistons unseat Do not remove one piston if the other is still seated Remove the pistons from the caliper Repeat this process for the other caliper half cau ti o n e y e h a z ar d Forced air will dislodge the caliper pistons rapidly which can lead to bodily injury or damage to the parts Point the caliper pistons toward a rubber surface before forcing air i...

Page 18: ...y excess fluid from the caliper halves There are two larger diameter pistons and two smaller diameter pistons Install one of each into each caliper half You can also use Avid DOT Grease or DOT 5 1 or 4 compatible grease as a lubricant 9 Remove the banjo port o ring from the outboard caliper half 10 Remove the o rings from the banjo bolt and banjo fitting Apply a small amount of DOT 5 1 fluid to th...

Page 19: ...banjo fitting onto the threads of the banjo bolt Turn the bolt into the fitting until it stops Do not tighten the banjo bolt yet Install the caliper body bolt and use a torque wrench with a T25 TORX bit socket to tighten it to 9 7 11 7 N m 86 104 in lb 12 Hold the banjo fitting at the desired angle Use a torque wrench with an 8 mm flare nut crowfoot to tighten the banjo bolt to 9 7 11 7 N m 86 104...

Page 20: ...y isopropyl alcohol on the caliper and clean it with a rag Visually check your work If there are any o rings that are protruding beyond the outside edges of the banjo or bolt remove and replace the o rings then repeat the installation process Overhauling the caliper introduces a small amount of air into the system It is necessary to bleed the brakes for optimal performance Click here for detailed ...

Page 21: ...curs the pads are contaminated and must be replaced For best results use only Avid High Performance 5 1 DOT Fluid If Avid fluid is not available only use DOT 5 1 or 4 fluid Do not use mineral oil or DOT 5 fluid Parts an d t o o l s nee d e d f o r ser v i ce Safety glasses Nitrile gloves Isopropyl alcohol Clean lint free rag Avid DOT Grease or DOT 5 1 or 4 compatible grease Hydraulic hose cutters ...

Page 22: ...ips out will create bubbles that you ll have to eliminate later Slide the nut down the hose and away from the end where you ll be cutting Do not pull the brake lever while the hose is removed 5 Determine where you need to cut the hose by holding it up to the lever in the position you like Leave a gentle bend in the hose with enough length to freely turn the bars all the way from side to side Doubl...

Page 23: ...hile holding the hose firmly use a T10 TORX to thread the hose barb into the end of the hose until it is flush Slide a new compression fitting over the end of the hose with the new hose barb 7 Push the hose firmly into the lever until it stops While holding the hose in place slide the compression fitting and compression nut up to the lever or hose stop ...

Page 24: ...torque For models with a compression nut only While continuing to push the hose into the lever body use an 8 mm flare nut wrench to tighten the compression nut to the proper torque If your compression fitting is alloy tighten to 5 N m 47 in lb If your compression fitting is steel tighten to 7 8 N m 70 in lb 9 Slide the boot back into place After completing the hose length adjustment bleed the brak...

Page 25: ...ever pour DOT fluid down a sewage or drainage system or into the ground or a body of water DOT fluids will damage painted surfaces If any fluid comes in contact with a painted surface i e your frame or printing on the brakes wipe it off immediately and clean with isopropyl alcohol or water Removal of paint and or printing by DOT fluid is not covered under warranty Do not allow any brake fluid to c...

Page 26: ...f the syringe Close the hose clamp on each syringe 2 De gas the fluid in the 1 2 full syringe Leave the hose clamp shut and pull on the plunger Bubbles will form in the brake fluid While the plunger is still pulled down lightly tap the syringe to release the bubbles sticking to the sides and the bottom so that they can rise to the top of the fluid When the bubbles stop forming and have all risen t...

Page 27: ...ps 7 For models equipped with Reach Adjust make sure the tip of the lever blade is 75 80 mm from the centerline of the handlebar If the lever is too far out it can make bleeding the brake impossible 8 Use the T10 TORX to remove the lever bleed port screw 9 Make sure the fluid in the 1 4 full syringe is pushed all the way to the tip so that there is no air gap then thread into the lever bleed port ...

Page 28: ...on the lever 12 Pull the brake lever all the way to the bar with your finger and hold it there until instructed to release the lever in a later step If you don t want to hold the lever with your finger have a friend hold it or you can fasten it with a zip tie or rubber band 13 Pull out on the caliper syringe plunger to create a vacuum then gently push in on the plunger to pressurize the system Rep...

Page 29: ...yringe from the caliper and reinstall the bleed port screw Use a clean rag to wipe off any excess DOT fluid that spills out as you reinstall the bleed port screw 16 Open the syringe clamp on the lever 17 Pull out on the lever syringe plunger to create a vacuum then gently push in on plunger to pressurize the system Squeeze and release the brake lever ten times allowing the lever to snap back to it...

Page 30: ...isually check your work Inspect the banjo bolt and banjo for any protruding o rings If there are any o rings that are squeezed beyond the outside edges of the banjo or bolt remove and replace the o rings and then repeat the installation process 21 Remove the Bleed Block from the caliper and reinstall the brake pads and spreader clip Click here for detailed brake pad installation instructions 22 Re...

Page 31: ...ads as shown Align the hole in the spreader clip with the holes in the brake pad tabs Squeeze the pad and clip assembly together then insert it into the caliper from the top of the caliper Push the pad clip assembly into the caliper until the holes in the spreader clip brake pads and caliper are aligned 5 Insert the pad retainer bolt into the outboard side of the caliper through the pad spreader a...

Page 32: ... heavy braking You must be familiar with the power and operation of disc brakes Braking heavily when not familiar with the power and operation of disc brakes could cause you to crash which could lead to serious injury and or death If you are unfamiliar with the power and operation of disc brakes you should have the bed in process performed by a qualified bicycle mechanic To safely achieve optimal ...

Page 33: ...www sram com ...

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